Continuous yarn



Feb. 8, 1938. M A s E m JR 2,107,838

CONTINUOUS YARN Filed May 1, 1935 INVENTOR Maurice fiLSa/e blQ/Ji:

Patented Feb. 8, 1938 g UNITED STATE PATENT OFFICE 12 Claims.

, approximately eight ounces of silk thread of the multiple strand, multiple twist type. In certain industries, however, such as the hosiery knitting industry and others, there is great objection to this commonly available package because it has too many knots, while the smaller packages require too much handling for commercial knitting or weaving. v

One of the principal objects of my invention is to produce a new yarn package of a continuous natural silk thread of a multiple strand, multiple twist type, such thread being knotless"in that it has no knots common to all strands, although individual strands which have breaks are separately tied.

Another object of my invention is to produce an eight ounce package of silk yarn especially suitable for hosiery tram which contains enough continuous silk thread to knit the leg portions of approximately one dozen pairs of hosiery, such thread being free of any multiplestrand-knots. A further, object of my invention is to provide a natural silk, multiple strand, multiple twist thread in which the strands are separately knotted at breaks or run-outs and in whichthe size of gthe yarn at the knotted portion-is not materially greater than at an-unknotted portion, such knotted portion passing through an opening sumclent to pass the maximum'diameterof an unknotted portion. A still further object ofmy invention is to pr vide a hosiery tram having single strand knots only, no knots being visible in a combination of yarns. n

A still further object of my invention is to provide a continuous length of natural silk yarn, separate strands of which are individually knotted, the knots being adjacent unknotted portions'jof. other strands, the strands of such thread being of uniform elasticity, strength and under uniform tension whereby such thread is especially adapted for knitting or weaving of elasticsilk productssuch as hosiery, etc.

i Another obiect of my invention is to provide a' superior. commercial, continuous silk yarn of low denierwhich is doubled and twisted to form a nimble strength such thread being free from knots as determined by freedom from pressoils or stoppage in knitting or weaving operations customarily caused by knots.

Further objects and advantages of my invention will appear from the following disclosure of a preferred form of embodiment thereof taken in 5- conjunction with the attached drawing which is illustrative thereof, and in which:

Figure 1 is an elevation of one form of my improved yarn package, and v Figure 2 is an enlarged view of my individually knotted strand yarn. Silk throwing includes as one of the preliminary steps, the winding of raw silk which in itself is too line and loosely held together to be a commercial product. This single end or strand is customarily doubled and twisted, sometimes in a one operation, and in sometypes of thread the single strand is twisted prior to doubling. Other treatment includescieaning, steaming, etc., and the final step is coning or forming a thread package. 7

Doubling forms multiple plies or strands for a sufliciently strong thread, and the number of strands varies for diflerent products. Hosiery tram, for example, commercially requires four or five strands or less for sheer leg portions and for service weight leg portions, welts, etc.,' the number of strands is usually greater and may be twelve or more, depending on the product desired.

In the various steps in winding and spinning, t the doubling operation is very important as a lesser number of strands in one portion than in another is fatal to acceptance forgrade. Stop motions have therefore been provided for stopping the receiving bobbin if a strand broke or ran out dueto exhaustion of the spool, and in some cases, operation of the stop motion has caused a severance of all strands so that the operator would be sure to tie a knot in a full number of the strands before the bobbin was restarted and the doubling continued. Coning also has always required the formation of knots in the larger packages due to joining thread. from two or more bobbins and under the best conditions prevailing at this time, an eight ounce package of natural silk yarn customarily has three or more knots common to all strands and may have a great many more. Ihave now found that I can produce a package of silk thread such as hosiery tram or other types suitable for weaving, knitting or direct use, which is as large or larger than any present commercial productnow available and in which the thread is continuous and has no knots common to all ends or strands. I can also produce such a product atareducedcostandlfindittobesuperior to other available products as to length, strength and quality.

My new continuous natural silk yarn differs from that of the best prior practice in that having no multiple strand knots, it has no knot defects which would show up in subsequent knitting or weaving operations. Inasmuch as the most carefully handled strands will break however, 1'

tie the broken ends of that strand only and do not break or destroy the remaining continuous strands. The individual knot of the knotted strand is then directly alongside and adjacent to the other strandswhich are continuous at that point and in a combination of yarns, is substantially invisible, even in the sheer type goods. My yarn may therefore be-termed knotless.

Furthermore, although natural silk thread is very fine in size, the separate strands, which are still finer or smaller, are not absolutely uniform in diameter. This results in a thread which has some variation. A single strand knot, however, is relatively so small that it does not cause rejects or become caught in needles or carriers of machines which pass the main thread. In addi- I can equally as well produce larger or smaller packages which are also knotless as desired, theeight ounce package is especially desirable for certain purposes. In hosiery tram, for example, this amount will make approximately two dozen separate stocking leg portions, or one dozen pairs. It is of course to be understood that the length of thread per pound varies with the number of strands, but as hosiery usually requires a small range of different strand threads, this is approximately correct. Asian example of this range, a half pound of seven strand thread 13/15 denier size will contain approximately 42,000 yards,

whereas, with a three strand thread 13/15 denier,-

the length is approximately 98,000 yards. With heavier denier, these amounts will be reduced, twenty thousand yards being the approximate lower limit of length of packages required in the knitting trade.

The yarn package of cone shape is wound on suitable coning machinery, theshowing of which has been omitted as unnecessary to an understanding of this invention. It is, of course, to he understood that the yarn package may be of other desired shapes such as a pineapple cone,

' modified pineapple cone,'quill, cop, parallel tube,

or the yarn may be retained on the bobbin for direct use. The shape of the package is variable in accordance with the desires of the knitters or weavers who find diiferent advantages in one over another.

The size'of the package is also variable within certain practical limits. Large size cones of ten ounces and over can be made successfully according to my invention, but the majority of silk yarn packages are in the common range of six to eight ounces. I can, of course, also'make small size-cones or packages in the range of two to five ounces, but these packages are usually not desirable for production in knitting machines as they require too much handling, dofilng and replenishment. Economy demands regularity of production which I can achieve for the first time with my larger sizes of cones.

My improved yarn is made on suitable machinery including winding, twisting and doubling machines. From the single end bobbins, I usually double the strands and I am particularly careful to stop the spindle of the doubler bobbin after a single end break with such rapidity that no twist takes place in the unbroken ends. I then separately knot the broken strand as shown at it without disturbing the continuous strands and then restart the doubler bobbin. I also prefer to use bobbins of a larger size than usual so that the doubler and twister bobbins will carry enough material to completely fill the desired size cone.

After doubling and subsequent operations are completed, I then form the package in a suitable standard type coning machine. Iprefer to cone from a doubler bobbin which is the same size as the cone package as I only use a single doubler bobbin and no knot is necessary. A substantial amount of time and waste is saved and I eliminate knots which would be between threads from different bobbins. V

' I am therefore able to produce a natural silk yarn of any desired continuous length, the respective strands of which are continuous adjacent any particular knot, and such knots, being in single strands only and usually spaced out of the range of visibility of the naked eye, are not conspicuous in a combination of yarns and do not add appreciably to the diameter of the thread. The yarn also has a uniform tension in every fiber or strand as I tie the necessary knots prior to tensioning the yarn and prior to twisting. As

g each fiber or strand is independent of each other,

- ucts. As an example, a knotless yarn hosiery tram made in accordance with my invention is especially desirable in making hosiery. As is well known, two of the major difflculties in knitting hosiery are press-ofis and throw-outs. Press-offs are due to knots in the tram catching in the carrier or the needle of the knitting machine, and at a break of the yarn, the particular knitted portion is discharged from the. machine.

Press-oflfs are a substantial loss to the operator, not only due to the fact that the particular stocking is not perfect, and because full production is not obtained, but in addition, the press-off is almost all waste. Under some circumstances, the yarn may be redrawn, but this is unsatisfactory.

Throw-outs are also caused by knots which appear on inspection of thefinal product. throw-outs are put in a lower quality class or thrown to waste, either of which is highly expensive and a cause of considerable loss. Throwouts and press-offs are eliminated in using my knotless yarn.

My hosiery tram has a further advantage in that within the range of quality of the silk, each stocking is uniform in grade and perfect. I obtain full production, lowered unit operating costs and therefore more economical operation of the knitting machines. The yarn is also uniformly elastic and the product is equal to the best Such ' turnsper inch, and two to twelve or more strands,

but it is also applicable to other thread products including organzine, grenadine and crepe. Organzineis a multiple strand thread, each strand of whichfis separately twisted and then after doubling, the thread is finally twisted. Grenadine is a highertwist modification of organzine having multiple strands,-each strand, of which receives a high initial twist, and then a further twist after doubling.

Crepe thread is a high twist multiple end on the side ofthe cone which will cause either gathering of other threads or cause unravelling.

There is no change of color of tint and there will be no change insise of.thread which frequently happened where separate threads were knotted together. Although there is great care used in selecting silk threads, there is such a variation in denier between threads of the same class that there is often a noticeable change where different threads are joined together. My knotlus yarn of the multiple strand type has no joint between different sections of the thread on one package as it is-continuous and at any one thread in which all strands are twisted together.\ point so many'of the strands are continuous that -Voileshave from thirty twists up and the crepes run in the order of seventy-five turns per inch.

This may vary somewhat more or less. I

Inasmuch as I tie single end knots, I do not interfere in any way with the twist of such-prodw .ucts. My knots are placed in' the individual strands prior to twisting and breaks or run-outs can be pieced together with substantially no variation in the total twist. This particularly overcomes slack twist in crepe and other high twist thread. v

My new yarn is also suitable for direct use such as in fish lines, racquet strings, and other .purposes in which a continuous, knotless yarn is required. In suggesting such uses, I do not intend gestive of the range of products for which my thread is'available. v v

Knotless silk yarn of my type has many other advantages of manufacture and use in addition to the improved quality of the yarn itself due to the elimination of the knots common to all strands. In throwing, I obtain greater production on the doubling, twisting and coning machines because of less dofllng and dofiing delays as larger spools absorb the entire amount of thread necessary to make the single package. There are fewer operations and this more than offsets any possible additional time required to tie single end knots. Greater production per machine and per operator results inmaterially increased economies, and I eliminate entirely, the. time and waste in tying knots in the coning operation as the final package ismade from a single bobbin.

Tying of single end knots is also far less wasteful of thread than the tying of multiple end knots which are commonly formed. With a multiple end knot common to all strands, the strands are usually drawn back'from the receiving bobbin and even if a careful knot is formed there are'of necessity ends that must be trimmed on all of the multiple strands. The waste is a very substantial factor and may run as-high as 6% of the entire production. 1

A single end knot eliminates redrawing of the strands properly wound on the receiving bobbin and makes it unnecessary to gather in, cut and waste portions of the other thread strands. With ,a typical five strand thread, there is far less than one fifth of the waste and under good operating conditions, I find that I can reduceall of the waste in throwing to less than one-half of that formerly thought necessary. With thread of a greater number of strands, greater economies are obtained.

'I'he yarn package is also far superior to the prioryarnpackagesinthattherecanbenoknots a knotted strand will have no noticeable efiect on the combination of yarns. There is also no two-tone appearance due to hard and soft threads which would effect dyeing.

Another important feature of my improved yarn package is that it has a uniform tension which is of considerable importance when the cone is placed in a subsequent machine of the knitting or weaving type. Heretofore at runouts of a bobbin in the coning operation, knots were tied and the thread from the new bobbin was started on the cone by hand. There was a sufficient diflerence in the manual winding that the tension would vary. to an objectionable degree and cause subsequent difficulties. As my yarn tolimit myself, however, as they are merely sugpackage is mechanically wound and as there is no interruption due to run-outs, a far superior yarn package results. Furthermore, there is substantially no possibility of knots opening in single end strands as the uniform tension is placedon the knotted strand and the unknotted strands after the knot is tied.

I am aware that products other than natural silk have been formed into continuous strands by various methods, and although I am aware that modifications may be made to my invention, I do not consider products other than natural silk within the scope of my invention except where they have substantially the same characteristics of size, use and quality common to natural silk. Natural silk is a small fiber which for hosiery tram is usually within the range of ten to twentyfive denier, although for other purposes it may be of five to thirty denier. It has a relatively high strength and elasticity, and due toits extremely small size or fineness, it is necessarily twisted and doubled for commercial use. My-invention is applicable to artificial silks having such characteristics.

It is also to be understood that knotting of two -or more strands at one point does not avoid my invention although it is not preferred. With a four strand silk thread for sheer hosiery, for

example, I find that I can knot two separate tionable. I It may happen that one strand breaking in the doubler will be adjacent a prior break inanotherstrandandinsuchcasatherewillbe two knots at the same point. This is so rare that it need not be especially considered and with four strand thread or more, it is of no importance.

It is of course to be understood that my invention relates to commercial products made on a production basis by throwing machines. I do not intend to cover the incidental or accidental production of a small quantity of knotless yarn, which because of the extremely high quality of silk, maybe free of all knots. It is recognized,

however, that silk throwing develops a large number of knots, the multiple end knots which are common to all strands, being the ones I eliminate. For production of yarn as well as subsequent products, this is a beneficial advance in the industry.

While I have shown a preferred form of embodiment of my invention, I am aware that other modifications within the scope and spirit of my invention may be made thereto,'and I therefore desire a broad interpretation of my invention limited only by the scope of the claims appended hereinafter,

I claim:

1. A continuoussilk hosiery tram for sheer leg portions of hosiery of the class described, said yarn being composed of a plurality of twisted natural silk strands of such length that during doubling and twisting breaks and run-outs in single strands will naturally occur, said strands having individual knots at breaks or run-outs, said yarn having no knots common to all strands.

2. As a new article of manufacture, knotless natural silk yarn having single strand knots only and not more than one single strandknot at any one point, each strand being a continuous length of the same lot of natural silk and having uniform denier, nature and twist.

3. A continuous silk yarn of the class described, said yarn being composed of a plurality of tinted twisted natural silk strands, said strands being individually knotted, each knot in one strand being adjacent continuous portions of the other strands and the silk of each strand being of the same tint, nature and twist.

" 4. A natural silk, multiple strand thread. of the class described, said thread having a uniform twist from end to end, said strands being continuous and having single strand knots at breaks or run-outs, each strand being entirely formed from a single skein of silk and having uniform twist, denier, nature and tint, so that there are no changes of silk from diiferent lots at any one point.

5. As a new'article of manufacture, a multiple twist, multiple strand natural silk knotless yarn having single strands separately knotted at breaks or run-outs during the doubling-twisting operation, saidknots being spaced along the yarn,

run-outs durlng the doubling-twisting operation, said knots being spaced along the yarn, there being no knots common to all strands, from two of the strands to two-thirds of all the strands being commonly knotted. I

7. A continuous natural silk yarn of the class described having a plurality of separate continuous strands of a length suitable for making approximately two dozen sheer stocking leg portions, said yarn having single strand knots formed 'at breaks or run-outs in the doubling-twisting operation and having no knots common to all strands, said strands having a continuously uniform twist whereby a knitted product made therefrom may be uniformly dyed.

8. As a new article of manufacture, a continuous yarn consisting of approximately eight ounces of wound natural silk yarn oi. 13/ 15 denier, and

between 'two and twelve strands, said yarn having vidually knotted where broken, each knot in a strand being adjacent continuous portions of the having uniform tension and substantially uniform strength.

10. As a new article of manufacture. a continuous yarn consisting of approximately eight ounces of wound natural silk yarn, said yarn having from two to twelve strands of five to thirty denier, said strandsbeing individually knotted and the knots in different strands being spaced a substantial distance apart, and without knots common to all strands, said yarn having a uniform twist throughout its length.

11. As a new article ofmanufacture, a crepe thread having about twenty turns to the inch, such thread being composed of a plurality of separate natural silk fibers, each of said fibers being separately continuous and having uniform tension, elongation and elasticity, certain of said fibers having knots individual thereto, the thread having no knots common to all fibers, each knot being'adiacent continuous portions of the other fibers and being formed prior to twist.

12. As a new article of manufacture, a continuous yarn of grenadine type equivalent in length to six ounces or more and having more. than two strands and not to exceed twelve strands, each of said strands being separately twisted in one direction, all of said strands also being twisted together, and in an opposite di-' rection, one of said strands beingknotted, said knot being within substantially uniform twisted I portions of the same strand, the twist of said yarn being set after the knots are formed.

, MAURICE A. SALEMIBIER, JR.

other strands, each of said separate strands 

